Pour in coolant and bleed engine cooling system

AR20.00-S-1142-03EH

Pour in coolant and bleed engine cooling system

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

Notes on coolant level

AH20.00-P-1142-01CW

Engine

622.8 in model 447

 Engine cooling

Number

Designation

Engine 622.851
except code H12 (Auxiliary hot-water heater)

Engine 622.851
with code H12 (Auxiliary hot-water heater)

BF20.00-N-1001-01A

Coolant

Total filling capacity

Liter

10,0

13,0

Corrosion/antifreeze down to -37 °C

Liter

5,0

6,5

Corrosion/antifreeze down to -45 °C

Liter

5,5

7,25

Sheet

BB00.40-P-0310-01A

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-06A

BB00.40-P-0325-06A

Sheet

BB00.40-P-0326-06A

BB00.40-P-0326-06A

Sheet

-

-

1

Fill coolant reservoir (7) with   coolant.

 The coolant level in the coolant reservoir (7) must exceed the maximum filling capacity of the engine cooling system by approx. 30%.
Otherwise air can be suctioned into the engine cooling system.

2

Bring the coolant reservoir (7) to the same height as the engine cooling system expansion reservoir.

3

 Attach the tester cap (1) to the engine cooling system expansion reservoir.

4

Attach control unit (2) to the  tester cap (1).

5

Attach venturi nozzle (3) to control unit (2).

6

Close feed valve (4) and drain valve (5).

7

Attach feed hose (6) to coolant reservoir (7).

8

Connect waste air hose (8) in an empty, suitable container.

9

Connect compressed-air hose (9) to venturi nozzle (3) and apply compressed air.

 To generate sufficient vacuum through the venturi nozzle (3), ensure compressed-air supply of at least 8 bar.

10

Open drain valve (5).

 A vacuum is generated in the engine cooling system.

11

Open the feed valve (4) briefly until the feed hose (6) is filled with the coolant and then close the feed valve (4) again.

12

Close drain valve (5) if display of the control unit (2) is in the green area.

13

Remove compressed-air hose (9) from the venturi nozzle (3).

14

Based on the indicator of the control unit (2), check whether the vacuum remains stable for 30 s.

If vacuum does not remain stable,



Check hoses, connections, and component parts of the engine cooling system, rectify the causes, and restart ventilation process.

15

Move switch (11) of  electric vacuum pump (18) to "0" position.

16

Connect the positive and negative terminals of the  electric vacuum pump (18) with a suitable 12 V voltage source (e.g. an on-board electrical system battery (G1)).

 Observe polarity of positive and negative terminals of  electric vacuum pump (18).

17

Hook the bracket (12), as shown, into the  NTKL adaptation (13).

18

Attach hose (14) to the  NTKL adaptation (13).

19

Close off shutoff valves (15, 16, 17).

20

Connect hose (20) to the  NTKL adaptation (13).

21

Remove Y-distributor from hose (20).

22

Remove venturi nozzle (3) from the control unit (2).

23

Attach hose (20) to the control unit (2).

 Fasten the hose (20) to the connection fitting of the drain valve (5) with a suitable clamp.

24

 Switch on electric vacuum pump (18).

25

Open stopcock (15).

 The feed valve (4) remains closed.

 The vacuum indicator (19) must indicate at least -0.9 bar.

If -0.9 bar is not reached,



Check cause, rectify it, and set up vacuum again.

26

Open drain valve (5) and evacuate entire engine cooling system for 5 minutes.

 While doing so, observe vacuum indicator (19).
The vacuum must remain stable at -0.9 bar.

If vacuum does not remain stable,



Check hoses, connections, and component parts of the engine cooling system, rectify causes, and repeat ventilation process and evacuation.

27

drain valve (5).

28

 Switch off electrical vacuum pump (18).

29

Remove hose (14) from  NTKL adaptation (13).

 The vacuum in the  NTKL adaptation (13) is disassembled as a result of this, until the vacuum indicator (19) displays 0.0 bar.

30

Based on the indicator of the control unit (2), check whether the vacuum remains stable for 30 s.

If vacuum does not remain stable,



Check hoses, connections, and component parts of the engine cooling system, rectify causes, and repeat ventilation process and evacuation.

31

Open feed valve (4).

 The engine cooling system is filled.

 The filling process ends when the indicator of the control unit (2) reaches 0.0 bar.

32

Open drain valve (5) as soon as coolant is no longer suctioned.

 The remaining existing vacuum will be removed in this way.

33

Remove control unit (2) with all connections.

34

Remove hose (20) from control unit (2).

35

Install Y-distributor on hose (20).

 Replace clamp.

36

 Remove electric vacuum pump (18) from  NTKL adaptation (13).

37

remove tester cap (1).

38

  Correct coolant level on the engine cooling system expansion reservoir.

 The coolant level may not exceed the maximum marking.